Polyethylene films

ABSTRACT

Films made from metallocene-catalyzed polyethylene polymers, optionally, with other polymers, are disclosed.

CROSS-REFERENCE OF RELATED APPLICATIONS

This application is a National Phase Application of International Application No. PCT/US2017/016922, filed Feb. 8, 2017, and claims the benefit of Ser. No. 62/313,502, filed on Mar. 25, 2016, which is herein incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention generally relates to polyethylene films made from metallocene-catalyzed polyethylene polymers, optionally, including other polymers.

BACKGROUND OF THE INVENTION

Metallocene polyethylene (mPE) resins such as those available from ExxonMobil Chemical Company, Houston, Tex., have revolutionized the plastics industry by improving upon polymer properties that have enhanced several end use applications and created several new ones. In general, mPE provides for a good balance of operational stability, extended output, versatility with higher alpha olefin (HAO) performance, toughness and strength, good optical properties, down gauging opportunities, and resin sourcing simplicity. See, for example, U.S. Patent Application Publication Nos. 2009/0297810, 2015/0291748, U.S. Pat. No. 6,956,088, and WO 2014/099356. However, for certain applications, more improvements are still required.

For example, edible and non-edible liquids are frequently packed in flexible packaging. Liquids are particularly demanding from a packaging standpoint because of mishandling, such as dropping the package from an elevated height that immediately stresses the walls of the package that may rupture the package or create leakage. Additionally, the liquid is in constant movement within the package during transportation and handling. This constant motion creates repeated flexion which may eventually create pinholes and leakage. Thus, liquid packaging applications face multiple technical and economical requirements.

A wide variety of packaging solutions have been proposed in the market place. They include simple polyethylene (PE) films, sophisticated multi-walls constructions, laminated structures, and multilayer films containing polyethylene and polyamide.

In other areas, container liners or flexi-tanks are used for the transportation of large quantities of liquid, typically above 10,000 liters. These applications represent the more demanding liquid packaging applications. They typically require an outer polypropylene fabric, a very thick PE film (e.g., 1000 μm) or several thinner PE films. Extreme toughness and flex crack resistance are required for these applications.

In yet in another area, bag-in-box is another way to pack liquids including edible and non-edible applications. Bag-in-box applications most often consist of a multi-wall bladder in a carton box in order to minimize the risk of pinholes and leakage. The bladder may have an outside wall consisting of a laminated structure, involving a barrier substrate and polyethylene film(s). The inside walls are typically polyethylene films. Excellent dart impact resistance is typically needed in order to withstand the shocks resulting from handling and transportation. Flex crack resistance of each individual film layer is also very important especially when thinner materials or reduced number of layers or walls are applied.

Another common way to pack liquids consists of using stand-up pouches in laminated structures, or VFFS pillow packs in laminated or non-laminated constructions. This type of liquid packaging usually involves smaller sizes (e.g., volumes ranging from 0.2 to 3 liters). Toughness, dart impact, and flex crack resistance are often required to guarantee package integrity. In particular, for flexible packaging of liquid and flowable materials, challenges remain with respect to, for example, repeated flex during transportation, handling, and storage. This repeated flex can lead to the formation of pinholes through which liquid or flowable materials can escape, generating waste and ruining the product. Holes in flexible food packaging can also compromise shelf-life. Additionally, flexible packaging must resist the trauma and shocks resulting from poor handling during the journey from the manufacturing site to the final end-use consumer. In extreme conditions, poor handling can create a very rapid increase of pressure onto the walls of the package such as a bag and make it burst.

Thus, there remains a need for improvements in films that may be used for flexible packaging for liquids and flowable materials. Such films would demonstrate a good balance of dart drop impact strength and/or flex crack resistance to enable enhanced performance, the flexibility to reformulate if desired, and/or down gauging possibilities.

SUMMARY OF THE INVENTION

In a class of embodiments, the invention provides for a film made from at least one polyethylene polymer comprising from 75.0 mol % to 100.0 mol % ethylene derived units and having: a density of from 0.910 g/cm³ to 0.923 g/cm³, a melt index (I_(2.16)) of from 0.1 g/10 min to 1.2 g/10 min, a melt index ratio (I_(21.6)/I_(2.16)) of from 20 to 35, and a weight average molecular weight (M_(w)) of from 150,000 g/mol to 400,000 g/mol; wherein the film has a dart drop impact strength (DIS) of ≥40 g/μm and flex crack resistance of ≤5 holes/10,000 cycles

Other embodiments of the invention are described, claimed herein and are apparent by the following disclosure.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Before the present polymers, compounds, components, compositions, and/or methods are disclosed and described, it is to be understood that unless otherwise indicated this invention is not limited to specific polymers, compounds, components, compositions, reactants, reaction conditions, ligands, metallocene structures, or the like, as such may vary, unless otherwise specified. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

It must also be noted that, as used in the specification and the appended claims, the singular forms “a.” “an” and “the” include plural referents unless otherwise specified.

Definitions

For the purposes of this disclosure, the following definitions will apply, unless otherwise stated:

molecular weight distribution (“MWD”) is equivalent to the expression M_(w)/M_(n). The expression M_(w)/M_(n) is the ratio of the weight average molecular weight (M_(w)) to the number average molecular weight (M_(n)). The weight average molecular weight is given by

$M_{w} = \frac{\sum\limits_{i}{n_{i}M_{i}^{2}}}{\sum\limits_{i}{n_{i}M_{i}}}$

the number average molecular weight is given by

$M_{n} = \frac{\sum\limits_{i}{n_{i}M_{i}}}{\sum\limits_{i}n_{i}}$

the z-average molecular weight is given by

$M_{z} = \frac{\sum\limits_{i}{n_{i}M_{i}^{3}}}{\sum\limits_{i}{n_{i}M_{i}^{2}}}$

where n_(i) in the foregoing equations is the number fraction of molecules of molecular weight M_(i). Measurements of M_(w), M_(z), and M_(n) are determined by Gel Permeation Chromatography. The measurements proceed as follows. Gel Permeation Chromatography (Agilent PL-220), equipped with three in-line detectors, a differential refractive index detector (DRI), a light scattering (LS) detector, and a viscometer, is used. Experimental details, including detector calibration, are described in: T. Sun, P. Brant, R. R. Chance, and W. W. Graessley, Macromolecules, Volume 34, Number 19, pp. 6812-6820, (2001). Three Agilent PLgel 10 m Mixed-B LS columns are used. The nominal flow rate is 0.5 mL/min, and the nominal injection volume is 300 μL. The various transfer lines, columns, viscometer and differential refractometer (the DRI detector) are contained in an oven maintained at 145° C. Solvent for the experiment is prepared by dissolving 6 grams of butylated hydroxytoluene as an antioxidant in 4 liters of Aldrich reagent grade 1,2,4-trichlorobenzene (TCB). The TCB mixture is then filtered through a 0.1 μm Teflon filter. The TCB is then degassed with an online degasser before entering the GPC-3D. Polymer solutions are prepared by placing dry polymer in a glass container, adding the desired amount of TCB, then heating the mixture at 160° C. with continuous shaking for about 2 hours. All quantities are measured gravimetrically. The TCB densities used to express the polymer concentration in mass/volume units are 1.463 g/ml at about 21° C. and 1.284 g/ml at 145° C. The injection concentration is from 0.5 to 2.0 mg/ml, with lower concentrations being used for higher molecular weight samples. Prior to running each sample, the DRI detector and the viscometer are purged. The flow rate in the apparatus is then increased to 0.5 ml/minute, and the DRI is allowed to stabilize for 8 hours before injecting the first sample. The LS laser is turned on at least 1 to 1.5 hours before running the samples. The concentration, c, at each point in the chromatogram is calculated from the baseline-subtracted DRI signal. I_(DRI), using the following equation: c=K _(DRI) I _(DRI)/(dn/dc) where K_(DRI) is a constant determined by calibrating the DRI, and (dn/dc) is the refractive index increment for the system. The refractive index, n=1.500 for TCB at 145° C. and λ=690 nm. Units on parameters throughout this description of the GPC-3D method are such that concentration is expressed in g/cm³, molecular weight is expressed in g/mole, and intrinsic viscosity is expressed in dL/g.

The LS detector is a Wyatt Technology High Temperature DAWN HELEOS. The molecular weight, M, at each point in the chromatogram is determined by analyzing the LS output using the Zimm model for static light scattering (M. B. Huglin, LIGHT SCATTERING FROM POLYMER SOLUTIONS, Academic Press, 1971):

$\frac{K_{o}c}{\Delta\;{R(\theta)}} = {\frac{1}{{MP}(\theta)} + {2\; A_{2}c}}$

Here, ΔR(θ) is the measured excess Rayleigh scattering intensity at scattering angle θ, c is the polymer concentration determined from the DRI analysis. A₂ is the second virial coefficient. P(θ) is the form factor for a monodisperse random coil, and K₀ is the optical constant for the system:

$K_{o} = \frac{4\;\pi^{2}{n^{2}\left( {{dn}/{dc}} \right)}^{2}}{\lambda^{4}N_{A}}$ where N_(A) is Avogadro's number, and (dn/dc) is the refractive index increment for the system, which take the same value as the one obtained from DRI method. The refractive index, n=1.500 for TCB at 145° C. and X=657 nm.

A high temperature Viscotek Corporation viscometer, which has four capillaries arranged in a Wheatstone bridge configuration with two pressure transducers, is used to determine specific viscosity. One transducer measures the total pressure drop across the detector, and the other, positioned between the two sides of the bridge, measures a differential pressure. The specific viscosity, ηs, for the solution flowing through the viscometer is calculated from their outputs. The intrinsic viscosity, [η], at each point in the chromatogram is calculated from the following equation: η_(s) =c[η]+0.3(c[η])² where c is concentration and was determined from the DRI output.

The branching index (g′_(vis)) is calculated using the output of the GPC-DRI-LS-VIS method as follows. The average intrinsic viscosity, [η]_(avg), of the sample is calculated by:

$\lbrack\eta\rbrack_{avg} = \frac{\sum{c_{i}\lbrack\eta\rbrack}_{i}}{\sum c_{i}}$ where the summations are over the chromatographic slices, i, between the integration limits.

The branching index g′_(vis) is defined as:

${g^{\prime}{vis}} = \frac{\lbrack\eta\rbrack_{avg}}{{kM}_{v}^{\alpha}}$ M_(v) is the viscosity-average molecular weight based on molecular weights determined by LS analysis. Z average branching index (g′_(Zave)) is calculated using Ci=polymer concentration in the slice i in the polymer peak times the mass of the slice squared, Mi². All molecular weights are weight average unless otherwise noted. All molecular weights are reported in g/mol unless otherwise noted. This method is the preferred method of measurement and used in the examples and throughout the disclosures unless otherwise specified. See also, for background, Macromolecules, Vol. 34, No. 19, Effect of Short Chain Branching on the Coil Dimensions of Polyolefins in Dilute Solution, Sun et al., pg. 6812-6820 (2001).

The broadness of the composition distribution of the polymer may be characterized by T₇₅-T₂₅. TREF is measured using an analytical size TREF instrument (Polymerchar, Spain), with a column of the following dimensions: inner diameter (ID) 7.8 mm, outer diameter (OD) 9.53 mm, and column length of 150 mm. The column may be filled with steel beads. 0.5 mL of a 4 mg/ml polymer solution in orthodichlorobenzene (ODCB) containing 2 g BHT/4 L were charge onto the column and cooled from 140° C. to −15° C. at a constant cooling rate of 1.0° C./min Subsequently, ODCB may be pumped through the column at a flow rate of 1.0 ml/min, and the column temperature may be increased at a constant heating rate of 2° C./min to elute the polymer. The polymer concentration in the eluted liquid may then be detected by means of measuring the absorption at a wavenumber of 2941 cm⁻¹ using an infrared detector. The concentration of the ethylene-α-olefin copolymer in the eluted liquid may be calculated from the absorption and plotted as a function of temperature. As used herein. T₇₅-T₂₅ values refer to where T₂₅ is the temperature in degrees Celsius at which 25% of the eluted polymer is obtained and T₇₅ is the temperature in degrees Celsius at which 75% of the eluted polymer is obtained via a TREF analysis. For example, in an embodiment, the polymer may have a T₇₅-T₂₅ value from 5 to 10, alternatively, a T₇₅-T₂₅ value from 5.5 to 10, and alternatively, a T₇₅-T₂₅ value from 5.5 to 8, alternatively, a T₇₅-T₂₅ value from 6 to 10, and alternatively, a T₇₅-T₂₅ value from 6 to 8, where T₇₅ is the temperature in degrees Celsius at which 25% of the eluted polymer is obtained and T₇₅ is the temperature in degrees Celsius at which 75% of the eluted polymer is obtained via temperature rising elution fractionation (TREF).

Polyethylene Polymer

The polyethylene polymer comprises from 70.0 mole % to or 100.0 mole % of units derived from ethylene. The lower limit on the range of ethylene content may be from 70.0 mole %, 75.0 mole %, 80.0 mole %, 85.0 mole %, 90.0 mole %, 92.0 mole %, 94.0 mole %, 95.0 mole %, 96.0 mole %, 97.0 mole %, 98.0 mole %, or 99.0 mole %/o based on the mole % of polymer units derived from ethylene. The polyethylene polymer may have an upper ethylene limit of 80.0 mole %, 85.0 mole %, 90.0 mole %, 92.0 mole %, 94.0 mole %, 95.0 mole %, 96.0 mole %, 97.0 mole %, 98.0 mole %, 99.0 mole %, 99.5 mole %, or 100.0 mole %, based on polymer units derived from ethylene. For polyethylene copolymers, the polyethylene polymer may have less than 50.0 mole % of polymer units derived from a C₃-C₂₀ olefin, preferably, an alpha-olefin, e.g., hexene or octene. The lower limit on the range of C₃-C₂₀ olefin-content may be 25.0 mole %, 20.0 mole %, 15.0 mole %, 10.0 mole %, 8.0 mole %, 6.0 mole %6, 5.0 mole %, 4.0 mole %, 3.0 mole %, 2.0 mole %, 1.0 mole %, or 0.5 mole %, based on polymer units derived from the C₃-C₂₀ olefin. The upper limit on the range of C₃-C₂₀ olefin-content may be 20.0 mole %, 15.0 mole %, 10.0 mole %, 8.0 mole %, 6.0 mole %, 5.0 mole %, 4.0 mole %, 3.0 mole %, 2.0 mole %, or 1.0 mole %, based on polymer units derived from the C₃ to C₂₀ olefin. Any of the lower limits may be combined with any of the upper limits to form a range. Comonomer content is based on the total content of all monomers in the polymer.

In a class of embodiments, the polyethylene polymer may have minimal long chain branching (i.e., less than 1.0 long-chain branch/1000 carbon atoms, preferably particularly 0.05 to 0.50 long-chain branch/1000 carbon atoms). Such values are characteristic of a linear structure that is consistent with a branching index (as defined below) of g′_(vis)≥0.980, 0.985, ≥0.99, ≥0.995, or 1.0. While such values are indicative of little to no long chain branching, some long chain branches may be present (i.e., less than 1.0 long-chain branch/1000 carbon atoms, preferably less than 0.5 long-chain branch/1000 carbon atoms, particularly 0.05 to 0.50 long-chain branch/1000 carbon atoms).

In some embodiments, the polyethylene polymers may have a density in accordance with ASTM D-4703 and ASTM D-1505/ISO 1183 of from about 0.910 to about 0.925 g/cm³, from about 0.910 to about 0.923 g/cm³, from about 0.910 to about 0.920 g/cm³, from about 0.915 to about 0.921 g/cm³, from about 0.910 to about 0.918 g/cm³, from about 0.912 to about 0.918 g/cm³, or from about 0.912 to 0.917 g/cm³.

The weight average molecular weight (M_(w)) of the polyethylene polymers may be from about 15,000 to about 500,000 g/mol, from about 20,000 to about 250,000 g/mol, from about 25,000 to about 150,000 g/mol, from about 150,000 to about 400,000 g/mol, from about 200,000 to about 400,000 g/mol, or from about 250,000 to about 350,000 g/mol.

The polyethylene polymers may have a molecular weight distribution (MWD) or (M_(w)/M_(n)) of from about 1.5 to about 5.0, from about 2.0 to about 4.0, from about 3.0 to about 4.0, or from about 2.5 to about 4.0.

The polyethylene polymers may have a z-average molecular weight (M_(z)) to weight average molecular weight (M_(w)) greater than about 1.5, or greater than about 1.7, or greater than about 2.0. In some embodiments, this ratio is from about 1.7 to about 3.5, from about 2.0 to about 3.0, or from about 2.2 to about 3.0.

The polyethylene polymers may have a melt index (MI) or (I_(2.16)) as measured by ASTM D-1238-E (190° C./2.16 kg) of about 0.1 to about 300 g/10 min, about 0.1 to about 100 g/10 min, about 0.1 to about 50 g/10 min, about 0.1 g/10 min to about 5.0 g/10 min, about 0.1 g/10 min to about 3.0 g/10 min, about 0.1 g/10 min to about 2.0 g/10 min, about 0.1 g/10 min to about 1.2 g/10 min, about 0.2 g/10 min to about 1.5 g/10 min, about 0.2 g/10 min to about 1.1 g/10 min, about 0.3 g/10 min to about 1.0 g/10 min, about 0.4 g/10 min to about 1.0 g/10 min, about 0.5 g/10 min to about 1.0 g/10 min, about 0.6 g/10 min to about 1.0 g/10 min, about 0.7 g/10 min to about 1.0 g/10 min, or about 0.75 g/10 min to about 0.95 g/10 min.

The polyethylene polymers may have a melt index ratio (MIR) (I_(21.6)/I_(2.16)) (as defined below) of from about 10.0 to about 50.0, from about 15.0 to about 45.0, from about 20.0 to about 40.0, from about 20.0 to about 35.0, from about 22 to about 38, from about 20 to about 32, from about 25 to about 31, or from about 28 to about 30.

In a class of embodiments, the polyethylene polymers may contain less than 5.0 ppm hafnium, less than 2.0 ppm hafnium, less than 1.5 ppm hafnium, or less than 1.0 ppm hafnium. In other embodiments, the polyethylene polymers may contain from about 0.01 ppm to about 2 ppm hafnium, from about 0.01 ppm to about 1.5 ppm hafnium, or from about 0.01 ppm to about 1.0 ppm hafnium.

Typically, the amount of hafnium is greater than the amount of zirconium in the polyethylene polymer. In a particular class of embodiments, the ratio of hafnium to zirconium (ppm/ppm) is at least about 2.0, at least about 10.0, at least about 15, at least about 17.0, at least about 20.0, at least about 25.0, at least about 50.0, at least about 100.0, at least about 200.0, or at least about 500.0 or more. While zirconium generally is present as an impurity in hafnium, it will be realized in some embodiments where particularly pure hafnium-containing catalysts are used, the amount of zirconium may be extremely low, resulting in an virtually undetectable or undetectable amount of zirconium in the polyethylene polymer. Thus, the upper limit on the ratio of hafnium to zirconium in the polymer may be quite large.

In several classes of embodiments, the polyethylene polymers may have at least a first peak and a second peak in a comonomer distribution analysis, therein the first peak has a maximum at a log(M_(w)) value of 4.0 to 5.4, 4.3 to 5.0, or 4.5 to 4.7; and a TREF elution temperature of 70.0° C. to 100.0° C., 80.0° C. to 95.0° C., or 85.0° C. to 90.0° C. The second peak in the comonomer distribution analysis has a maximum at a log(M_(w)) value of 5.0 to 6.0, 5.3 to 5.7, or 5.4 to 5.6; and a TREF elution temperature of 40.0° C. to 60.0° C., 45.0° C. to 60.0° C., or 48.0° C. to 54.0° C.

In any of the embodiments described above, the polyethylene polymer may have one or more of the following properties: a melt index (MI) (190° C./2.16 kg) of from about 0.1 g/10 min to about 5.0 g/10 min; a melt index ratio (MIR) of from about 15 to about 30; a M_(w) of from about 20,000 to about 200,000 g/mol: a M_(w)/M_(n) of from about 2.0 to about 4.5; and a density of from about 0.910 to about 0.925 g/cm³. In any of these embodiments, the amount of hafnium is greater than the amount of zirconium and a ratio of hafnium to zirconium (ppm/ppm) may be at least about 2.0, at least about 10.0, at least about 15.0, at least about 17.0, at least about 20.0, or at least about 25.0.

In several of the classes of embodiments described above, the polyethylene polymer may have an orthogonal comonomer distribution. The term “orthogonal comonomer distribution” is used herein to mean across the molecular weight range of the ethylene polymer, comonomer contents for the various polymer fractions are not substantially uniform and a higher molecular weight fraction thereof generally has a higher comonomer content than that of a lower molecular weight fraction. The term “substantially uniform comonomer distribution” is used herein to mean that comonomer content of the polymer fractions across the molecular weight range of the ethylene-based polymer vary by <10.0 wt %. In some embodiments, a substantially uniform comonomer distribution may refer to <8.0 wt %, <5.0 wt %, or <2.0 wt %. Both a substantially uniform and an orthogonal comonomer distribution may be determined using fractionation techniques such as gel permeation chromatography-differential viscometry (GPC-DV), temperature rising elution fraction-differential viscometry (TREF-DV) or cross-fractionation techniques.

Materials and processes for making the polyethylene polymer have been described in, for example, U.S. Pat. No. 6,956,088, particularly Example 1; U.S. Patent Application Publication No. 2009/0297810, particularly Example 1; U.S. Patent Application Publication No. 2015/0291748, particularly PE1-PE5 in the Examples; and WO 2014/099356, particularly PE3 referenced on page 12 and in the Examples, including the use of a silica supported hafnium transition metal metallocene/methylalumoxane catalyst system described in, for example, U.S. Pat. Nos. 6,242,545 and 6,248,845, particularly Example 1.

The polyethylene polymer is commercially available from ExxonMobil Chemical Company, Houston, Tex., and sold under Exceed XP™ metallocene polyethylene (mPE). Exceed XP™ mPE offers step-out performance with respect to, for example, dart drop impact strength, flex-crack resistance, and machine direction (MD) tear, as well as maintaining stiffness at lower densities. Exceed XP™ mPE also offers optimized solutions for a good balance of melt strength, toughness, stiffness, and sealing capabilities which makes this family of polymers well-suited for blown film/sheet solutions.

Additional Polymers

Additional polymers may be combined with the polyethylene polymer described above in a blend in a monolayer film or in one or more layers in a multilayer film or structure. The additional polymers may include other polyolefin polymers such as the following ethylene-based and/or propylene-based polymers.

First Additional Polyethylene Polymer

The first additional polyethylene polymers are ethylene-based polymers having about 99.0 to about 80.0 wt %, 99.0 to 85.0 wt %, 99.0 to 87.5 wt %, 99.0 to 90.0 wt %, 99.0 to 92.5 wt %, 99.0 to 95.0 wt %, or 99.0 to 97.0 wt %, of polymer units derived from ethylene and about 1.0 to about 20.0 wt %, 1.0 to 15.0 wt %, 1.0 to 12.5 wt %, 1.0 to 10.0 wt %, 1.0 to 7.5 wt %, 1.0 to 5.0 wt %, or 1.0 to 3.0 wt % of polymer units derived from one or more C₃ to C₂₀ α-olefin comonomers, preferably C₃ to C₁₀ α-olefins, and more preferably C₄ to C₈ α-olefins. The α-olefin comonomer may be linear, branched, cyclic and/or substituted, and two or more comonomers may be used, if desired. Examples of suitable comonomers include propylene, butene, 1-pentene; 1-pentene with one or more methyl, ethyl, or propyl substituents; 1-hexene; 1-hexene with one or more methyl, ethyl, or propyl substituents: 1-heptene; 1-heptene with one or more methyl, ethyl, or propyl substituents; 1-octene; 1-octene with one or more methyl, ethyl, or propyl substituents; 1-nonene; 1-nonene with one or more methyl, ethyl, or propyl substituents; ethyl, methyl, or dimethyl-substituted 1-decene; 1-dodecene; and styrene. Particularly suitable comonomers include 1-butene, 1-hexene, and 1-octene, 1-hexene, and mixtures thereof.

In an embodiment of the invention, the first additional polyethylene polymer comprises from about 8 wt % to about 15 wt %, of C₃-C₁₀ α-olefin derived units, and from about 92 wt % to about 85 wt % ethylene derived units, based upon the total weight of the polymer.

In another embodiment of the invention, the first additional polyethylene polymer comprises from about 9 wt % to about 12 wt %, of C₃-C₁₀ α-olefin derived units, and from about 91 wt % to about 88 wt % ethylene derived units, based upon the total weight of the polymer.

The first additional polyethylene polymers may have a melt index (MI), I_(2.16) or simply 12 for shorthand according to ASTM D1238, condition E (190° C./2.16 kg) reported in grams per 10 minutes (g/10 min), of ≥about 0.10 g/10 min, e.g., ≥about 0.15 g/10 min, ≥about 0.18 g/10 min, ≥about 0.20 g/10 min, ≥about 0.22 g/10 min, ≥about 0.25 g/10 min, ≥about 0.28, or ≥about 0.30 g/10 min. Additionally, the first additional polyethylene polymers may have a melt index (I_(2.16))≤about 3.0 g/10 min, ≤about 2.0 g/10 min, ≤about 1.5 g/10 min, ≤about 1.0 g/10 min. 5 about 0.75 g/10 min, ≤about 0.50 g/10 min, ≤about 0.40 g/10 min, ≤about 0.30 g/10 min, ≤about 0.25 g/10 min, ≤about 0.22 g/10 min, ≤about 0.20 g/10 min, ≤about 0.18 g/10 min, or 5≤about 0.15 g/10 min. Ranges expressly disclosed include, but are not limited to, ranges formed by combinations any of the above-enumerated values, e.g., from about 0.1 to about 3.0, about 0.2 to about 2.0, about 0.2 to about 0.5 g/10 min, etc.

The first additional polyethylene polymers may also have High Load Melt Index (HLMI), I_(21.6) or I₂₁ for shorthand, measured in accordance with ASTM D-1238, condition F (190° C./21.6 kg). For a given polymer having an MI and MIR as defined herein, the HLMI is fixed and can be calculated in accordance with the following paragraph.

The first additional polyethylene polymers may have a Melt Index Ratio (MIR) which is a dimensionless number and is the ratio of the high load melt index to the melt index, or I_(21.6)/I_(2.16) as described above. The MIR of the first additional polyethylene polymers may be from 25 to 80, alternatively, from 25 to 60, alternatively, from about 30 to about 55, and alternatively, from about 35 to about 50.

The first additional polyethylene polymers may have a density ≥about 0.905 g/cm³, ≥about 0.910 g/cm³, ≥about 0.912 g/cm³, ≥about 0.913 g/cm³, ≥about 0.915 g/cm³, ≥about 0.916 g/cm³, ≥about 0.917 g/cm³, ≥about 0.918 g/cm³. Additionally or alternatively, first additional polyethylene polymers may have a density ≤about 0.945 g/cm³, e.g., ≤about 0.940 g/cm³, ≤about 0.937 g/cm³, ≤about 0.935 g/cm³, ≤about 0.930 g/cm³, ≤about 0.925 g % cm³, ≤about 0.920 g/cm³, or ≤about 0.918 g/cm³. Ranges expressly disclosed include, but are not limited to, ranges formed by combinations any of the above-enumerated values, e.g., from about 0.905 to about 0.945 g/cm³, 0.910 to about 0.935 g/cm³, 0.912 to 0.930 g/cm³, 0.916 to 0.925 g/cm³, 0.918 to 0.920 g/cm³, etc. Density is determined using chips cut from plaques compression molded in accordance with ASTM D-1928 Procedure C, aged in accordance with ASTM D-618 Procedure A, and measured as specified by ASTM D-1505.

Typically, although not necessarily, the first additional polyethylene polymers may have a molecular weight distribution (MWD, defined as M_(w)/M_(n)) of about 2.5 to about 5.5, preferably 3.0 to 4.0.

The melt strength of a polymer at a particular temperature may be determined with a Gottfert Rheotens Melt Strength Apparatus. To determine the melt strength, a polymer melt strand extruded from the capillary die is gripped between two counter-rotating wheels on the apparatus. The take-up speed is increased at a constant acceleration of 2.4 mm/sec². The maximum pulling force (in the unit of cN) achieved before the strand breaks or starts to show draw-resonance is determined as the melt strength. The temperature of the rheometer is set at 190° C. The capillary die has a length of 30 mm and a diameter of 2 mm. The polymer melt is extruded from the die at a speed of 10 mm/sec. The distance between the die exit and the wheel contact point should be 122 mm. The melt strength of polymers of embodiments of invention may be in the range from about 1 to about 100 cN, about 1 to about 50 cN, about 1 to about 25 cN, about 3 to about 15 cN, about 4 to about 12 cN, or about 5 to about 10 cN.

The first additional polyethylene polymers (or films made therefrom) may also be characterized by an averaged 1% secant modulus (M) of from 10,000 to 60,000 psi (pounds per square inch), alternatively, from 20,000 to 40,000 psi, alternatively, from 20,000) to 35,000 psi, alternatively, from 25,000 to 35,000 psi, and alternatively, from 28,000 to 33,000 psi, and a relation between M and the dart drop impact strength in g/mil (DIS) complying with formula (A): DIS≥0.8*[100+e ^((11.71-0.000268M+2.183×10) ⁻⁹ ^(M) ² ⁾],  (A) where “e” represents 2.7183, the base Napierian logarithm, M is the averaged modulus in psi, and DIS is the 26 inch dart impact strength. The DIS is preferably from about 120 to about 1000 g/mil, even more preferably, from about 150 to about 800 g/mil.

The branching index, g′ is inversely proportional to the amount of branching. Thus, lower values for g′ indicate relatively higher amounts of branching. The amounts of short and long-chain branching each contribute to the branching index according to the formula: g′=g′_(LCB)×g′_(SCB).

Typically, the first additional polyethylene polymers have a g′vis of 0.85 to 0.99, particularly, 0.87 to 0.97, 0.89 to 0.97, 0.91 to 0.97, 0.93 to 0.95, or 0.97 to 0.99.

The first additional polyethylene polymers may be made by any suitable polymerization method including solution polymerization, slurry polymerization, supercritical, and gas phase polymerization using supported or unsupported catalyst systems, such as a system incorporating a metallocene catalyst.

As used herein, the term “metallocene catalyst” is defined to comprise at least one transition metal compound containing one or more substituted or unsubstituted cyclopentadienyl moiety (Cp) (typically two Cp moieties) in combination with a Group 4, 5, or 6 transition metal, such as, zirconium, hafnium, and titanium.

Metallocene catalysts generally require activation with a suitable co-catalyst, or activator, in order to yield an “active metallocene catalyst”, i.e., an organometallic complex with a vacant coordination site that can coordinate, insert, and polymerize olefins. Active catalyst systems generally include not only the metallocene complex, but also an activator, such as an alumoxane or a derivative thereof (preferably methyl alumoxane), an ionizing activator, a Lewis acid, or a combination thereof. Alkylalumoxanes (typically methyl alumoxane and modified methylalumoxanes) are particularly suitable as catalyst activators. The catalyst system may be supported on a carrier, typically an inorganic oxide or chloride or a resinous material such as, for example, polyethylene or silica.

Zirconium transition metal metallocene-type catalyst systems are particularly suitable. Non-limiting examples of metallocene catalysts and catalyst systems useful in practicing the present invention include those described in, U.S. Pat. Nos. 5,466,649, 6,476,171, 6,225,426, and 7,951,873, and in the references cited therein, all of which are fully incorporated herein by reference. Particularly useful catalyst systems include supported dimethylsilyl bis(tetrahydroindenyl) zirconium dichloride.

Supported polymerization catalyst may be deposited on, bonded to, contacted with, or incorporated within, adsorbed or absorbed in, or on, a support or carrier. In another embodiment, the metallocene is introduced onto a support by slurrying a presupported activator in oil, a hydrocarbon such as pentane, solvent, or non-solvent, then adding the metallocene as a solid while stirring. The metallocene may be finely divided solids. Although the metallocene is typically of very low solubility in the diluting medium, it is found to distribute onto the support and be active for polymerization. Very low solubilizing media such as mineral oil (e.g., Kaydo™ or Drakol™) or pentane may be used. The diluent can be filtered off and the remaining solid shows polymerization capability much as would be expected if the catalyst had been prepared by traditional methods such as contacting the catalyst with methylalumoxane in toluene, contacting with the support, followed by removal of the solvent. If the diluent is volatile, such as pentane, it may be removed under vacuum or by nitrogen purge to afford an active catalyst. The mixing time may be greater than 4 hours, but shorter times are suitable.

Typically in a gas phase polymerization process, a continuous cycle is employed where in one part of the cycle of a reactor, a cycling gas stream, otherwise known as a recycle stream or fluidizing medium, is heated in the reactor by the heat of polymerization. This heat is removed in another part of the cycle by a cooling system external to the reactor. (See e.g., U.S. Pat. Nos. 4,543,399; 4,588,790; 5,028,670; 5,317,036; 5,352,749; 5,405,922; 5,436,304; 5,453,471; 5,462,999; 5,616,661; and 5,668,228.) To obtain the first additional polyethylene polymers, individual flow rates of ethylene, comonomer, and hydrogen should be controlled and adjusted to obtain the desired polymer properties.

Suitable commercial polymers for the first additional polyethylene polymer are available from ExxonMobil Chemical Company as Enable™ metallocene polyethylene (mPE) resins.

Second Additional Polyethylene Polymer

The second additional polyethylene polymers are ethylene-based polymers comprising ≥50.0 wt % of polymer units derived from ethylene and ≤50.0 wt % preferably 1.0 wt % to 35.0 wt %, even more preferably 1 to 6 wt % of polymer units derived from a C₃ to C₂₀ alpha-olefin comonomer (for example, hexene or octene).

The second additional polyethylene polymer may have a density of ≥about 0.910 g/cm³, ≥about 0.915 g/cm³, ≥about 0.920 g/cm³, ≥about 0.925 g/cm³, ≥about 0.930 g/cm³, or ≤about 0.940 g/cm³. Alternatively, the second polyethylene polymer may have a density of 5 about 0.950 g/cm³, e.g., ≤about 0.940 g/cm³, ≤about 0.930 g/cm³, ≤about 0.925 g/cm³, ≤about 0.920 g/cm³, or ≤about 0.915 g/cm³. Ranges expressly disclosed include ranges formed by combinations any of the above-enumerated values, e.g., 0.910 to 0.950 g/cm³, 0.910 to 0.930 g/cm³, 0.910 to 0.925 g/cm³, etc. Density is determined using chips cut from plaques compression molded in accordance with ASTM D-1928 Procedure C, aged in accordance with ASTM D-618 Procedure A, and measured as specified by ASTM D-1505.

The second additional polyethylene polymer may have a melt index (I_(2.16)) according to ASTM D1238 (190° C./2.16 kg) of ≥about 0.5 g/10 min., e.g., ≥about 0.5 g/10 min., ≥about 0.7 g/10 min., ≥about 0.9 g/10 min., ≥about 1.1 g/10 min., ≥about 1.3 g/10 min., ≥about 1.5 g/10 min., or ≥about 1.8 g/10 min. Alternatively, the melt index (I_(2.16)) may be ≤about 8.0 g/10 min., ≤about 7.5 g/10 min., ≤about 5.0 g/10 min., ≤about 4.5 g/10 min., ≤about 3.5 g/10 min., ≤about 3.0 g/10 min., ≤about 2.0 g/10 min., e.g., 5 about 1.8 g/10 min., ≤about 1.5 g/10 min., ≤about 1.3 g/10 min., ≤about 1.1 g/10 min., ≤about 0.9 g/10 min., or 5 about 0.7 g/10 min., 0.5 to 2.0 g/10 min., particularly 0.75 to 1.5 g/10 min. Ranges expressly disclosed include ranges formed by combinations any of the above-enumerated values, e.g., about 0.5 to about 8.0 g/10 min., about 0.7 to about 1.8 g/10 min., about 0.9 to about 1.5 g/10 min., about 0.9 to 1.3, about 0.9 to 1.1 g/10 min, about 1.0 g/10 min., etc.

In particular embodiments, the second additional polyethylene polymer may have a density of 0.910 to 0.920 g/cm³, a melt index (I_(2.16)) of 0.5 to 8.0 g/10 min., and a CDBI of 60.0% to 80.0%, preferably between 65% and 80%.

The second polyethylene polymers are generally considered linear. Suitable second additional polyethylene polymers are available from ExxonMobil Chemical Company under the trade name Exceed™ metallocene (mPE) resins. The MIR for Exceed materials will typically be from about 15 to about 20.

Third Additional Polyethylene Polymer

The third additional polyethylene polymers may be a copolymer of ethylene, and one or more polar comonomers or C₃ to C₁₀ α-olefins. Typically, the third additional polyethylene polymer includes 99.0 wt % to about 80.0 wt %, 99.0 wt % to 85.0 wt %, 99.0 wt % to 87.5 wt %, 95.0 wt % to 90.0 wt %, of polymer units derived from ethylene and about 1.0 to about 20.0 wt %, 1.0 wt % to 15.0 wt %, 1.0 wt % to 12.5 wt %, or 5.0 wt % to 10.0 wt % of polymer units derived from one or more polar comonomers, based upon the total weight of the polymer. Suitable polar comonomers include, but are not limited to: vinyl ethers such as vinyl methyl ether, vinyl n-butyl ether, vinyl phenyl ether, vinyl beta-hydroxy-ethyl ether, and vinyl dimethylamino-ethyl ether; olefins such as propylene, butene-1, cis-butene-2, trans-butene-2, isobutylene, 3,3,-dimethylbutene-1, 4-methylpentene-1, octene-1, and styrene; vinyl type esters such as vinyl acetate, vinyl butyrate, vinyl pivalate, and vinylene carbonate; haloolefins such as vinyl fluoride, vinylidene fluoride, tetrafluoroethylene, vinyl chloride, vinylidene chloride, tetrachloroethylene, and chlorotrifluoroethylene; acrylic-type esters such as methyl acrylate, ethyl acrylate, n-butyl acrylate, t-butyl acrylate, 2-ethylhexyl acrylate, alpha-cyanoisopropyl acrylate, beta-cyanoethyl acrylate, o-(3-phenylpropan-1,3,-dionyl)phenyl acrylate, methyl methacrylate, n-butyl methacrylate, t-butyl methacrylate, cyclohexyl methacrylate, 2-ethylhexyl methacrylate, methyl methacrylate, glycidyl methacrylate, beta-hydroxethyl methacrylate, beta-hydroxpropyl methacrylate, 3-hydroxy-4-carbo-methoxy-phenyl methacrylate, N,N-dimethylaminoethyl methacrylate, t-butylaminoethyl methacrylate, 2-(1-aziridinyl)ethyl methacrylate, diethyl fumarate, diethyl maleate, and methyl crotonate; other acrylic-type derivatives such as acrylic acid, methacrylic acid, crotonic acid, maleic acid, methyl hydroxy maleate, itaconic acid, acrylonitrile, fumaronitrile, N,N-dimethylacrylamide, N-isopropylacrylamide, N-t-butylacrylamide, N-phenylacrylamide, diacetone acrylamide, methacrylamide, N-phenylmethacrylamide, N-ethylmaleimide, and maleic anhydride; and other compounds such as allyl alcohol, vinyltrimethylsilane, vinyltriethoxysilane, N-vinylcarbazole, N-vinyl-N-methylacetamide, vinyldibutylphosphine oxide, vinyldiphenylphosphine oxide, bis-(2-chloroethyl) vinylphosphonate, and vinyl methyl sulfide.

In some embodiments, the third additional polyethylene polymer is an ethylene/vinyl acetate copolymer having about 2.0 wt % to about 15.0 wt %, typically about 5.0 wt % to about 10.0 wt %, polymer units derived from vinyl acetate, based on the amounts of polymer units derived from ethylene and vinyl acetate (EVA). In certain embodiments, the EVA resin can further include polymer units derived from one or more comonomer units selected from propylene, butene, 1-hexene, 1-octene, and/or one or more dienes.

Suitable dienes include, for example, 1,4-hexadiene, 1,6-octadiene, 5-methyl-1,4-hexadiene, 3,7-dimethyl-1,6-octadiene, dicyclopentadiene (DCPD), ethylidene norbomene (ENB), norbomadiene, 5-vinyl-2-norbomene (VNB), and combinations thereof.

Suitable third additional polyethylene polymers include Escorene™ Ultra EVA resins, Escor™ EAA resins, ExxonMobil™ EnBA resins, and Optema™ EMA resins available from ExxonMobil Chemical Company, Houston, Tex.

Fourth Additional Polyethylene Polymer

The fourth additional polyethylene polymers are generally heterogeneously branched ethylene polymers. The term “heterogeneously branched ethylene polymer” refers to an polymer having polymer units derived from ethylene and preferably at least one C₃-C₂₀ alpha-olefin and having a CDBI <50.0%. Typically, such polymers are the result of a Ziegler-Natta polymerization process. Such polymers are also referred to as Linear Low Density Polyethylene Polymers or LLDPEs, more particularly sometimes as ZN LLDPEs.

Heterogeneously branched ethylene polymers differ from the homogeneously branched ethylene polymers primarily in their branching distribution. For example, heterogeneously branched LLDPE polymers have a distribution of branching, including a highly branched portion (similar to a very low density polyethylene), a medium branched portion (similar to a medium branched polyethylene) and an essentially linear portion (similar to linear homopolymer polyethylene). The amount of each of these fractions varies depending upon the whole polymer properties desired. For example, a linear homopolymer polyethylene polymer has neither branched nor highly branched fractions, but is linear.

Heterogeneously branched ethylene polymer polymers typically have a CDBI <50.0%, preferably <45.0%, <40.0%, <35.0%, <30.0%, <25.0%, or <20.0%. In particular embodiments the CDBI of the heterogeneously branched ethylene polymer is 20.0 to <50.0%, 20.0 to 45.0%, 20.0 to 35.0%, 20.0 to 30.0%, 20.0 to 25.0%, 25.0 to 30.0%, 25.0 to 35.0%, 25.0 to 40.0%, 25.0 to 45.0%, 30.0 to 35.0%, 30.0 to 40.0%, 30.0 to 45.0%, 30.0 to <50.0%, 35.0 to 40.0%, 35.0 to <50.0%, 40.0 to 45.0%, or 40.0 to <50.0%.

The heterogeneously branched ethylene polymer typically comprises 80 to 100 mole % of polymer units derived from ethylene and 0 to 20.0 mole % of polymer units derived from at least one C₃ to C₂₀ alpha-olefin, preferably the alpha olefin has 4 to 8 carbon atoms. The content of comonomer is determined based on the mole fraction based on the content of all monomers in the polymer.

The content of polymer units derived from alpha-olefin in the heterogeneously branched ethylene polymer may be any amount consistent with the above ranges for ethylene. Some preferred amounts are 2.0 to 20.0 mole %, 2.0 to 15.0 mole %, or 5.0 to 10.0 mole %, particularly where the polymer units are derived from one or more C₄-C₈ alpha-olefins, more particularly butene-1, hexene-1, or octene-1.

Heterogeneously branched ethylene polymers may have a density ≤0.950 g/cm³, preferably ≤0.940 g/cm³, particularly from 0.915 to about 0.950 g/cm³, preferably 0.920 to 0.940 g/cm³.

The melt index, I_(2.16), according to ASTM D-1238-E (190° C./2.16 kg) of the heterogeneously branched ethylene polymer is generally from about 0.1 g/10 min. to about 100.0 g/10 min.

Suitable heterogeneously branched ethylene polymers and other polyethylene polymers include ExxonMobil™ Linear Low Density Polyethylene (LLDPE) and ExxonMobil™ NTX Super hexene copolymer available from ExxonMobil Chemical Company, Houston. Tex.

A fifth additional polyethylene polymer may also be present as High Density Polyethylene (HDPE). The HDPE may be unimodal or bimodal/multimodal and have a narrow molecular weight distribution (MWD) or broad MWD.

A sixth additional polyethylene polymer may also be present as Low Density Polyethylene made from a High Pressure Polymerization Process. Suitable resins include Nexxstar™ resins available from ExxonMobil and other LDPE's.

Propylene-Based Polymer

Propylene-based polymers are also contemplated. A suitable propylene-based polymer or elastomer (“PBE”) comprises propylene and from about 5 wt/o to about 25 wt %° of one or more comonomers selected from ethylene and/or C₄-C₁₂ α-olefins. In one or more embodiments, the α-olefin comonomer units may be derived from ethylene, butene, pentene, hexene, 4-methyl-1-pentene, octene, or decene. The embodiments described below are discussed with reference to ethylene as the α-olefin comonomer, but the embodiments are equally applicable to other copolymers with other α-olefin comonomers. In this regard, the copolymers may simply be referred to as propylene-based polymers with reference to ethylene as the α-olefin.

In one or more embodiments, the PBE may include at least about 2 wt %, at least about 3 wt %, at least about 4 wt %, at least about 5 wt %, at least about 6 wt %, at least about 7 wt %, or at least about 8 wt %, or at least about 9 wt %, or at least about 10 wt %, or at least about 12 wt % ethylene-derived units. In those or other embodiments, the PBE may include up to about 30 wt %, or up to about 25 wt %, or up to about 22 wt %, or up to about 20 wt %, or up to about 19 wt %, or up to about 18 wt %, or up to about 17 wt % ethylene-derived units, where the percentage by weight is based upon the total weight of the propylene-derived and α-olefin derived units. Stated another way, the PBE may include at least about 70 wt %, or at least about 75 wt %, or at least about 80 wt %, or at least about 81 wt % propylene-derived units, or at least about 82 wt % propylene-derived units, or at least about 83 wt % propylene-derived units, and in these or other embodiments, the PBE may include up to about 95 wt %, or up to about 94 wt %, or up to about 93 wt %, or up to about 92 wt %, or up to about 90 wt %, or up to about 88 wt % propylene-derived units, where the percentage by weight is based upon the total weight of the propylene-derived and α-olefin derived units. In certain embodiments, the PBE may comprise from about 5 wt % to about 25 wt % ethylene-derived units, or from about 9 wt % to about 18 wt % ethylene-derived units.

The PBEs of one or more embodiments are characterized by a melting point (Tm), which can be determined by differential scanning calorimetry (DSC). For purposes herein, the maximum of the highest temperature peak is considered to be the melting point of the polymer. A “peak” in this context is defined as a change in the general slope of the DSC curve (heat flow versus temperature) from positive to negative, forming a maximum without a shift in the baseline where the DSC curve is plotted so that an endothermic reaction would be shown with a positive peak.

In one or more embodiments, the Tm of the PBE (as determined by DSC) is less than about 115° C., or less than about 110° C., or less than about 100° C., or less than about 95° C., or less than about 90° C.

In one or more embodiments, the PBE may be characterized by its heat of fusion (Hf), as determined by DSC. In one or more embodiments, the PBE may have an Hf that is at least about 0.5 J/g, or at least about 1.0 J/g, or at least about 1.5 J/g, or at least about 3.0 J/g, or at least about 4.0 J/g, or at least about 5.0 J/g, or at least about 6.0 J/g, or at least about 7.0 J/g. In these or other embodiments, the PBE may be characterized by an Hf of less than about 75 J/g, or less than about 70 J/g, or less than about 60 J/g, or less than about 50 J/g, or less than about 45 J/g, or less than about 40 J/g, or less than about 35 J/g, or less than about 30 J/g.

As used within this specification, DSC procedures for determining Tm and Hf include the following. The polymer is pressed at a temperature of from about 200° C. to about 230° C. in a heated press, and the resulting polymer sheet is hung, at about 23° C., in the air to cool. About 6 to 10 mg of the polymer sheet is removed with a punch die. This 6 to 10 mg sample is annealed at about 23° C. for about 80 to 100 hours. At the end of this period, the sample is placed in a DSC (Perkin Elmer Pyris One Thermal Analysis System) and cooled at a rate of about 10° C./min to about −50° C. to about −70° C. The sample is heated at a rate of about 10° C./min to attain a final temperature of about 200° C. The sample is kept at 200° C. for 5 minutes and a second cool-heat cycle is performed. Events from both cycles are recorded. The thermal output is recorded as the area under the melting peak of the sample, which typically occurs between about 0° C. and about 200° C. It is measured in Joules and is a measure of the Hf of the polymer.

The PBE can have a triad tacticity of three propylene units, as measured by 13C NMR, of 75% or greater, 80% or greater, 85% or greater, 90% or greater, 92% or greater, 95% or greater, or 97% or greater. In one or more embodiments, the triad tacticity may range from about 75 to about 99%, or from about 80 to about 99%, or from about 85 to about 99%, or from about 90 to about 99%, or from about 90 to about 97%, or from about 80 to about 97%. Triad tacticity is determined by the methods described in U.S. Pat. No. 7,232,871.

The PBE may have a tacticity index ranging from a lower limit of 4 or 6 to an upper limit of 8 or 10 or 12. The tacticity index, expressed herein as “m/r”, is determined by ¹³C nuclear magnetic resonance (“NMR”). The tacticity index, m/r, is calculated as defined by H. N. Cheng in 17 MACROMOLECULES 1950 (1984). The designation “m” or “r” describes the stereochemistry of pairs of contiguous propylene groups, “m” referring to meso and “r” to racemic. An m/r ratio of 1.0 generally describes a syndiotactic polymer, and an m/r ratio of 2.0 an atactic material. An isotactic material theoretically may have a ratio approaching infinity, and many by-product atactic polymers have sufficient isotactic content to result in ratios of greater than 50.

In one or more embodiments, the PBE may have a % crystallinity of from about 0.5% to about 40%, or from about 1% to about 30%, or from about 5% to about 25%, determined according to DSC procedures. Crystallinity may be determined by dividing the Hf of a sample by the Hf of a 100% crystalline polymer, which is assumed to be 189 joules/gram for isotactic polypropylene or 350 joules/gram for polyethylene.

In one or more embodiments, the PBE may have a density of from about 0.85 g/cm³ to about 0.92 g/cm³, or from about 0.86 g/cm³ to about 0.90 g/cm³, or from about 0.86 g/cm³ to about 0.89 g/cm³ at room temperature, as measured per the ASTM D-792.

In one or more embodiments, the PBE can have a melt index (MI) (ASTM D-1238-E, 2.16 kg @ 190° C.), of less than or equal to about 100 g/10 min. or less than or equal to about 50 g/10 min, or less than or equal to about 25 g/10 min, or less than or equal to about 10 g/10 min, or less than or equal to about 9.0 g/10 min, or less than or equal to about 8.0 g/10 min, or less than or equal to about 7.0 g/10 min.

In one or more embodiments, the PBE may have a melt flow rate (MFR), as measured according to ASTM D-1238-E (2.16 kg weight, 230° C.), greater than about 1 g/10 min, or greater than about 2 g/10 min, or greater than about 5 g/10 min, or greater than about 8 g/10 min. or greater than about 10 g/10 min. In the same or other embodiments, the PBE may have an MFR less than about 500 g/10 min, or less than about 400 g/10 min, or less than about 300 g/10 min, or less than about 200 g/10 min, or less than about 100 g/10 min, or less than about 75 g/10 min, or less than about 50 g/10 min. In certain embodiments, the PBE may have an MFR from about 1 to about 100 g/10 min, or from about 2 to about 75 g/10 min, or from about 5 to about 50 g/l 0 min.

Suitable commercially available propylene-based polymers include Vistamaxx™ Performance Polymers from ExxonMobil Chemical Company and Versify™ Polymers from The Dow Chemical Company, Midland, Mich.

The propylene-based polymers may also include polypropylene homopolymers and/or other polypropylene copolymers. For these types of polymers, the term propylene-based polymer refers to a homopolymer, copolymer, or impact copolymer including >50.0 mol % of polymer units derived from propylene. Some useful propylene-based polymers include those having one or more of the following properties:

-   1) propylene content of at least 85 wt. % (preferably at least 90     wt. %, preferably at least 95 wt. %, preferably at least 97 wt. %,     preferably 100 wt. %): -   2) M_(w) of 30 to 2,000 kg/mol (preferably 50 to 1,000 kg/mol,     preferably 90 to 500 kg/mol): -   3) M_(w)/M_(n) of 1 to 40 (preferably 1.4 to 20, preferably 1.6 to     10, preferably 1.8 to 3.5, preferably 1.8 to 2.5); -   4) branching index (g′) of 0.2 to 2.0 (preferably 0.5 to 1.5,     preferably 0.7 to 1.3, preferably 0.9 to 1.1); -   5) melt flow rate (MFR) of 1 to 300 dg/min (preferably 5 to 150     dg/min, preferably 10 to 100 dg/min, preferably 20 to 60 dg/min); -   6) melting point of at least 100° C. (preferably at least 110° C.,     preferably at least 120° C., preferably at least 130° C., preferably     at least 140° C., preferably at least 150° C., preferably at least     160° C., preferably at least 165° C.); -   7) crystallization temperature (T_(c), peak) of at least 70° C.     (preferably at least 90° C., preferably at least 110° C., preferably     at least 130° C.); -   8) heat of fusion (H_(f)) of 40 to 160 J/g (preferably 50 to 140     J/g, preferably 60 to 120 J/g, preferably 80 to 100 J/g); -   9) crystallinity of 5 to 80% (preferably 10 to 75%, preferably 20 to     70%, preferably 30 to 65%, preferably 40 to 60%); -   10) propylene meso diads of 90% or more (preferably 92% or more,     preferably 94% or more, preferably 96% or more); -   11) heat deflection temperature (HDT) of 45 to 140° C. (preferably     60 to 135° C., preferably 75 to 125° C.); -   12) Gardner impact strength at 23° C. of 30 to 1300 J (preferably 40     to 800 J, preferably 50 to 600 J); and/or -   13) flexural modulus of 300 to 3000 MPa (preferably 600 to 2500 MPa,     preferably 800 to 2000 MPa, preferably 1000 to 1500 MPa).

In a class of embodiments, the propylene-based polymer is selected from polypropylene homopolymers, polypropylene copolymers, and blends or mixtures thereof. The homopolymer may be atactic polypropylene, isotactic polypropylene, highly isotactic polypropylene, syndiotactic polypropylene, and blends or mixtures thereof. The copolymer may be a random copolymer, a statistical copolymer, a block copolymer, and blends or mixtures thereof.

The method of making the propylene-based polymers is not critical, as they may be made by slurry, solution, gas-phase, high-pressure, or other suitable processes, through the use of catalyst systems appropriate for the polymerization of polyolefins, such as Ziegler-Natta-type catalysts, metallocene-type catalysts, other appropriate catalyst systems, or combinations thereof.

In a preferred embodiment the propylene-based polymers are made by the catalysts, activators and processes described in U.S. Pat. No. 6,342,566. U.S. Pat. No. 6,384,142. WO 03/040201, WO 97/19991 and U.S. Pat. No. 5,741,563. Such catalysts are well known in the art, and are described in, for example, ZIEGLER CATALYSTS (Gerhard Fink, Rolf Mülhaupt and Hans H. Brintzinger, eds., Springer-Verlag 1995); Resconi et al., Selectivity in Propene Polymerization with Metallocene Catalysts, 100 CHEM. REV., pp. 1253-1345 (2000); and I, II METALLOCENE-BASED POLYOLEFINS (Wiley & Sons, 2000).

Suitable propylene-based polymers include Achieve™ resins, ExxonMobil™ Polypropylene resins, and Exxtral™ Performance Polyolefins available from ExxonMobil Chemical Company. Houston, Tex.

Polymer Blends

The films may include monolayer films made from blends of the polymers described above or multilayer films of two or more layers comprising a “neat” polymer or a blend of the polymers described above, optionally, blended with other polymers, additives, processing aids etc.

For example, in a class of embodiments, the film may comprise two or more layers. The two or more layers may comprise at least one skin layer, a core layer, and optionally, one or more intermediary layers. Each layer may comprise a “neat” polymer with optional processing aids and/or additives or may comprise a blend of polymers with optional processing aids and/or additives.

The at least one of the skin layer, the core layer, or optional intermediary layer may comprise from 1 wt % to 100 wt %, from 30 wt % to 100 wt %, from 40 wt % to 100 wt %, from 50 wt % to 100 wt %, from 60 wt % to 100 wt %, or from 75 wt % to 100 wt %, of the polyethylene polymer, based upon the total weight of the respective skin layer, the core layer, or optional intermediary layer.

In a class of embodiments, the at least one of the skin layer, the core layer, or optional intermediary layer, may further comprise, for example, in a blend, at least one different polyethylene polymer and/or a polypropylene polymer. In some embodiments, the at least one different polyethylene polymer is a linear low density polyethylene polymer.

Additives

The polymers and compositions described above may be used in combination with the following additives and other components.

First Antioxidant

The first antioxidant comprises one or more antioxidants. They include, but are not limited to, hindered phenols, for example, octadecyl-3-(3,5-di-tert.butyl-4-hydroxyphenyl)-propionate (CAS 002082-79-3) commercially available as IRGANOX™ 1076, pentaerythritol tetrakis (3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate) (CAS 6683-19-8) commercially available as IRGANOX™ 1010; and combinations thereof.

They may be combined with one or more polymers in range from 100 to 4000 parts by weight of the first antioxidant, based on one million parts of the polymer or polymer composition, alternatively, from 250 to 3000 parts by weight of the first antioxidant, based on one million parts of the polymer or polymer composition, alternatively, from 500 to 2500 parts by weight of the first antioxidant, based on one million parts of the polymer or polymer composition, alternatively, from 750 to 2500 parts by weight of the first antioxidant, based on one million parts of the polymer or polymer composition, alternatively, from 750 to 2000 parts by weight of the first antioxidant, based on one million parts of the polymer or polymer composition, and alternatively, from 1000 to 2000 parts by weight of the first antioxidant, based on one million parts of the polymer or polymer composition.

Second Antioxidant

The second antioxidant comprises one or more antioxidants. They include, but are not limited to, liquid phosphites, such as C₂-C₇, preferably C₂-C₄, and alkyl aryl phosphites mixed structures. Non-limiting examples include mono-amylphenyl phosphites, di-amylphenyl phosphites, dimethylpropyl phosphites, 2-methylbutanyl phosphites, and combinations thereof. In several embodiments of the invention, the second antioxidant may also be represented by the formula [4-(2-methylbutan-2-yl)phenyl]_(x)[2,4-bis(2-methylbutan-2-yl)phenyl]_(3-x) phosphate, wherein x=0, 1, 2, 3, or combinations thereof.

Such antioxidants and their use with polyolefin polymers have been described in U.S. Patent Application Nos. 2005/0113494, 2007/0021537, 2009/0326112, 2013/0190434, 2013/225738, 2014/0045981 and U.S. Pat. Nos. 5,254,709, 6,444,836, 7,888,414, 7,947,769, 8,008,383, 8,048,946, 8,188,170, and 8,258,214. An example of a commercially available liquid phosphite is sold under the tradename WESTON™ 705 (Addivant, Danbury, Conn.).

The second antioxidant may be combined with one or more polymers in the range from 100 to 4000 parts by weight of the second antioxidant, based on one million parts of the polymer or polymer composition; alternatively, from 250 to 3000 parts by weight of the second antioxidant, based on one million parts of the polymer or polymer composition, alternatively, from 300 to 2000 parts by weight of the second antioxidant, based on one million parts of the polymer or polymer composition, alternatively, from 400 to 1450 parts by weight of the second antioxidant, based on one million parts of the polymer or polymer composition, alternatively, from 425 to 1650 parts by weight of the second antioxidant, based on one million parts of the polymer or polymer composition, and alternatively, from 1 to 450 parts by weight of the second antioxidant, based on one million parts of the polymer or polymer composition.

The polymers and/or compositions comprising the first antioxidant and/or the second antioxidant described above may be used in combination with the following neutralizing agents, additional additives and other components.

Neutralizing Agents

One or more neutralizing agents (also called catalyst deactivators) include, but are not limited to, calcium stearate, zinc stearate, calcium oxide, synthetic hydrotalcite, such as DHT4A, and combinations thereof.

Additional Additives and Other Components

Additional additives and other components include, but are limited to, fillers (especially, silica, glass fibers, talc, etc.) colorants or dyes, pigments, color enhancers, whitening agents, cavitation agents, anti-slip agents, lubricants, plasticizers, processing aids, antistatic agents, antifogging agents, nucleating agents, stabilizers, mold release agents, and other antioxidants (for example, hindered amines and phosphates). Nucleating agents include, for example, sodium benzoate and talc. Slip agents include, for example, oleamide and erucamide.

End Use Applications

Any of the polymers and compositions in combination with the additives and other components described herein may be used in a variety of end-use applications. Such end uses may be produced by methods known in the art. Exemplary end-use applications include but are not limited to films, film-based products, diaper components such as backsheets, housewrap, wire and cable coating compositions, articles formed by molding techniques, e.g., injection or blow molding, extrusion coating, foaming, casting, and combinations thereof. End uses also include several products made from films, e.g., bags, packaging, and personal care films, pouches, medical products, such as for example, medical films and intravenous (IV) bags.

Films

In certain classes of embodiments, specific end use films include, for example, cast films, stretch films, stretch/cast films, stretch cling films, stretch handwrap films, machine stretch wrap, shrink films, shrink wrap films, green house films, laminates, and laminate films. Exemplary films are prepared by any conventional technique known to those skilled in the art, such as for example, techniques utilized to prepare blown, extruded, and/or cast stretch and/or shrink films (including shrink-on-shrink applications).

In particular, the films may be used to fabricate structures for flowable materials and liquid packaging, such as pouches made from multilayer films where stiffness and toughness, flex crack resistance, and sealability and machinability become paramount properties to the end use application. Exemplary applications include but are not limited to bag-in-box packaging, non-laminated pillow packs, flexible food packaging, laminates, laminated constructions such as stand-up pouches and pillow packs, thicker films for large containers, etc. Some of these examples have been described in, for example, U.S. Pat. No. 5,972,443.

As used herein, the term “flowable material” refers to materials that are flowable under gravity or may be pumped or moved by some other mechanical means. Such materials include liquids, e.g., milk, water, soda, flavored waters, fruit juice, wine, beer, spirits, oil; emulsions, e.g., ice cream mix, soft margarine: pastes, e.g., meat pastes, peanut butter; preserves, e.g., jams, pie fillings, marmalade; jellies; doughs: ground meat e.g., sausage meat; powders e.g., gelatin powders, detergents: granular solids e.g., nuts, sugar: and like materials.

In a class of embodiments, multilayer films or multiple-layer films may be formed by methods well known in the art such as coextrusion. For example, the materials forming each layer may be coextruded through a coextrusion feedblock and die assembly to yield a film with two or more layers adhered together but differing in composition. Coextrusion can be adapted for use in both cast film or blown film processes.

Exemplary multilayer films have at least two, at least three, or at least four layers. In one embodiment the multilayer films are composed of five to ten layers. With reference to multilayer film structures of the invention comprising the same or different layers, the following notation may be used for illustration. Each layer of a film is denoted “A” or “B”. Where a film includes more than one A layer or more than one B layer, one or more prime symbols (′,″,′″, etc.) are appended to the A or B symbol to indicate layers of the same type that can be the same or can differ in one or more properties, such as chemical composition, density, melt index, thickness, etc. Finally, the symbols for adjacent layers are separated by a slash (/). Using this notation, a three-layer film having an inner layer of the polyethylene resin or blend of the invention between two outer, film layers would be denoted A/B/A′. Similarly, a five-layer film of alternating layers would be denoted A/B/A′/B′/A″. Unless otherwise indicated, the left-to-right or right-to-left order of layers does not matter, nor does the order of prime symbols; e.g., an A/B film is equivalent to a B/A film, and an A/A′/B/A″ film is equivalent to an A/B/A′/A″ film.

In another class of embodiments, and using the nomenclature described above, the present invention provides multilayer films with any of the following exemplary structures: (a) two-layer films, such as A/B and B/B′; (b) three-layer films, such as A/B/A′, A/A′/B, B/A/B′ and B′B′/B″; (c) four-layer films, such as A/A′/A″/B, A/A′/B/A″, AA′B/B′, A/B/A′/B′, A/B/B′A′. B/A/A′/B′, A/B/B′/B″, B/A/B′/B″ and B/B′/B″/B′″; (d) five-layer films, such as AA′/A″ A′″/B, A/A′/A″/B/A′″, A/A′B/A″/A′″, A/A′, A″/B/B′, A/A′/B/A″/B′, A/A′B/B′/A″, AB/A′/B′/A″, A/B/A′/A″/B, B/A/A′/A″/′B′, A/A′/B/B′B″, A/B/A′B′/B″, A′B/B′/B″/A′, B/A/A′/B′/B″, B/A/B′/A′/B″, B/A/B′/B″/A′, A/B/B′B″/B′″, B/A/B′/B″/B′″, B/B′/A′B″/B′″, and B′B′/B″B′″/B″″; and similar structures for films having six, seven, eight, nine, ten, eleven, twelve, thirteen, fourteen, fifteen, sixteen, seventeen, eighteen, nineteen, twenty, or more layers. It should be appreciated that films having still more layers, for example, films that comprise nanolayers, may be formed using the polymers and blends of the invention, and such films are within the scope of the invention.

The films may further be embossed, or produced or processed according to other known film processes.

The films may be tailored to specific applications by adjusting the thickness, materials and order of the various layers, as well as the additives and other components in each layer. The total thickness of a monolayer or multilayer films may vary based upon the application desired. A total film thickness of from about 1.0 mil to about 5.0 mil is suitable for many applications. Alternative embodiments include from about 1.5 mil to about 4.0 mil, from about 2.0 mil to about 4.0 mil, from about 2.5 mil to about 4.0 mil, or from about 3.0 mil to about 4.0 mil. In another class of embodiments, the film may have a film thickness of ≥1 mil, a film thickness of ≥3 mil, or a film thickness of ≥5 mil. Those skilled in the art will appreciate that the thickness of individual layers may be adjusted based on the desired end use application and performance, resin(s) employed, equipment capability, desired output and operability constraints, and other factors.

In any of the embodiments described herein, the film may be measured for flex crack resistance. Flex crack resistance may be measured using the Gelbo flex test method. It is useful for simulating the flexing and bending conditions imposed on, for example, flexible packaging films. This simulation gives an indication about the real-life treatment of packed products during transport and/or storage.

The Gelbo flex test method and flex crack utilizes a Gelbo Flex Tester, model 5000, available from United States Testing Company, Inc. The Gelbo Flex Tester consists of a 3.5 inch diameter stationary head, and a 3.5 inch diameter movable head, spaced at a distance of 7 inch, face to face. The shoulders (0.5 inch wide) on each head, are used to fix the test specimen. The motion of the movable head is controlled by a grooved, reciprocating shaft. The stroke of the shaft is adjustable from 6 inch to 3.5 inch, to accommodate the testing of the materials. The flexing speed is 40 cycles per minute and a full cycle consists of one forward stroke and one return stroke. The grooved shaft is so designed that by requiring the 6 inch movement stroke, one obtains a twisting motion of 440° during the first 3.5 inch travel, followed by a straight horizontal 2.5 inch travel.

The Gelbo flex test method is performed at about 21° C. The test begins with cutting a film sample at the following dimensions: length=22 cm (film transverse direction) and width=30 cm (film machine direction). The handwheel on the motor shaft is turned to bring the circular heads to their maximum opened positions. The film sample is installed and the clamps are closed. The sliding door is closed and the counter is then set to 10,000 cycles. The test is initiated until completion of the cycles. Once completed, the test sample is formed into a bag. The bag is placed in a vacuum chamber filled with water, and the pressure in the chamber is decreased down to a pressure of 213 mbar (atmospheric pressure-800 mbar) that cause the bag to inflate. Air escapes from the holes, which are then counted. The number of holes in the sample is the value of the film's flex crack resistance. The lower the number of holes, the better the flex crack resistance.

In a class of embodiments, the films may have a flex crack resistance ≤7 holes/10,000 cycles, a flex crack resistance ≤6 holes/10.000 cycles, a flex crack resistance ≤5 holes/10,000 cycles, a flex crack resistance of ≤4 holes/10,000 cycles, a flex crack resistance of ≤3 holes/10,000 cycles, a flex crack resistance ≤2 holes/10,000 cycles, or a flex crack resistance ≤1 hole/10,000 cycles.

In any of the embodiments described herein, the film may be measured for Dart Drop Impact or Dart Drop Impact Strength (DIS), reported in grams (g), (g/mil), or (g/μm) and measured as in accordance with ASTM D-1709, method A. The dart head is phenolic. It calculates the impact failure weight, i.e., the weight for which 50% of the test specimens will fail under the impact.

In a class of embodiments, the films may have a dart drop impact strength (DIS) of ≥500 g/mil, a dart drop impact strength (DIS) of ≥750 g/mil, a dart drop impact strength (DIS) of ≥1,000 g/mil, a dart drop impact strength (DIS) of ≥1,500 g/mil, a dart drop impact strength (DIS) of ≥2,000 g/mil, or a dart drop impact strength (DIS) of ≥2,250 g/mil.

Alternatively, the films may have a dart drop impact strength (DIS) of ≥30 g/μm, a dart drop impact strength (DIS) of ≥40 g/μm, a dart drop impact strength (DIS) of ≥50 g/l m, a dart drop impact strength (DIS) of ≥60 g/μm, a dart drop impact strength (DIS) of ≥70 g/μm, or a dart drop impact strength (DIS) of ≥80 g/μm.

Test Methods

The properties cited below were determined in accordance with the following test procedures. Where any of these properties is referenced in the appended claims, it is to be measured in accordance with the specified test procedure.

Where applicable, the properties and descriptions below are intended to encompass measurements in both the machine and transverse directions. Such measurements are reported separately, with the designation “MD” indicating a measurement in the machine direction, and “TD” indicating a measurement in the transverse direction.

Film thickness, reported in microns, was measured using a Measuretech Series 200 instrument. The instrument measures film thickness using a capacitance gauge. For each film sample, ten film thickness data points were measured per inch of film as the film was passed through the gauge in a transverse direction. From these measurements, an average gauge measurement was determined and reported.

1% Secant Modulus (M), reported in megapascal (MPa), was measured as specified by ASTM D-882. The average modulus (AVG modulus) is the arithmetic average of 1% secant moduli measured in machine direction (MD) and transverse direction (TD).

Dart F₅₀, or Dart Drop Impact or Dart Drop Impact Strength (DIS) was measured as specified by ASTM D-1709, method A, as stated above.

Needle Puncture Maximum Force and Needle Puncture Energy at Break were measured by the method CEN 14477. This test method covers the determination of puncture resistance of flexible packaging materials. The method proceeds with a film sample that is fastened in a sample specimen holder. A penetration probe made of hardened steel with rounded tip (0.8 mm diameter) is pushed through the film sample at a constant test speed (100 mm/min). The force is measured by a load cell and the deformation of the film sample is measured by the travel of the cross-head. The energy required to penetrate through the entire film is calculated from the force-travel curve.

EXAMPLES

It is to be understood that while the invention has been described in conjunction with the specific embodiments thereof, the foregoing description is intended to illustrate and not limit the scope of the invention. Other aspects, advantages and modifications will be apparent to those skilled in the art to which the invention pertains.

Therefore, the following examples are put forth so as to provide those skilled in the art with a complete disclosure and description and are not intended to limit the scope of that which the inventors regard as their invention.

Example 1

PE 1 and PE 2 resins were made according to U.S. Patent Application Publication No. 2015/0291748, inventive examples, referencing U.S. Pat. No. 6,956,088, and using the bis(n-propylcyclopentadienyl)HfCl₂/MAO catalyst system disclosed therein under polymerization conditions to produce the polyethylene polymers having certain MI's, densities, and MIR's as indicated. These polymer properties were obtained by varying the polymerization conditions and/or hydrogen concentration as known to those skilled in the art.

PE 1 had a density of 0.916 g/cm³, a melt index (I_(2.16)) of 0.5 g/10 min, a melt index ratio (I_(21.6)/I_(2.16)) of 30. PE 2 had a density of 0.912 g/cm³, a melt index (I_(2.16)) of 0.5 g/10 min, a melt index ratio (I_(2.16)/I_(2.16)) of 31. These samples were evaluated along with Exceed™ mPE 1012HA, Exceed™ mPE 1015HA, Exceed™ mPE 1018HA, and Enable™ mPE 20-05HH, all mLLDPE grades available from ExxonMobil Chemical Company, Houston, Tex.

Examples of comparative and inventive polyethylene blown films were made by a blown film line having an 80 mm (2½ inch) extruder with 30 L/D ratio LLDPE screw, 15.2 cm (6 inch) diameter die, and dual lip air ring with chilled air at about 15° C. (60° F.). The films had a thickness of 25.4 μm (1 mil).

TABLE 1 Film processing conditions Exceed Exceed Exceed Enable 1012HA 1015HA 1018HA 20-05HH PE 1 PE 2 Melt pressure (psi) 4050 4160 3870 4510 3904 4420 Melt temp. (° F.) 402 402 410 401 409 415 Output (lbs/hr/in die) 10.19 10.04 9.84 10.08 10 9.92 Gauge (mils) 1.02 1 0.98 1 1 1 FLH (in) 30 26 23 21 21 21 Die gap (mil) 60 60 60 30 60 60 BUR 2.5 2.5 2.5 2.5 2.5 2.5

TABLE 2 Flex crack performance (number of holes/10,000cycles) Test 1 Test 2 Test 3 Test 4 Average Exceed 1018HA 15 19 16 15 16 Exceed 1015HA 3 5 4 6 5 Exceed 1012HA 3 5 4 6 5 Enable 20-05HH 12 9 7 13 10 PE 1 2 2 3 2 2 PE 2 1 3 0 0 1

Table 2 shows a very low number of holes for films made from PE 1 and PE 2 after 10,000 flexion cycles.

Example 2

PE 3 and PE 4 were made according to U.S. Patent Application Publication No. 2015/0291748, inventive examples, referencing U.S. Pat. No. 6,956,088, and using the bis(n-propylcyclopentadienyl)HfCl₂/MAO catalyst system disclosed therein under polymerization conditions to produce the polyethylene polymers having certain MI's, densities, and MIR's as indicated. These polymer properties were obtained by varying the polymerization conditions as known to those skilled in the art.

PE 3 had a density of 0.918 g/cm³, a melt index (I_(2.16)) of 0.5 g/10 min, a melt index ratio (I_(21.6)/I_(2.16)) of 29. PE 4 had a density of 0.918 g/cm³, a melt index (I_(2.16)) of 1.0 g/10 min, a melt index ratio (I_(21.6)/I_(2.16)) of 28.

Several 5-layer 50 μm (2 mil) film structures were produced on a Windmoeller & Hoelscher line with a die diameter of 280 mm (11 inch) and a die gap of 1.4 mm (55 mil). All films were produced with blow-up ratio of 2.5, an output of 200 kg/h and a frost line around 950 mm. All films had a 1/2/9/2/1 layer distribution, with all skins and subskins belonging to one film having the same composition in order to simulate AB/A films with 1/3/1 layer distribution. Temperature of the outside cooling air was 21° C. and the temperature of the cooling air inside the bubble was 15° C. Additional equipment characteristics are reported in Table 3.

The polymers used and the processing conditions are reported in Table 4 and Table 5. Other polymers used in the structures include Elite™ 5400GS and Affinity™ PL 1881G, available from The Dow Chemical Company, and LLDPE LL1001XV commercially available from ExxonMobil Chemical Company. Also included is a 0.907 gram/cm³ density, 1.0 gram/10 min index ultra low density linear C₂/C₈ copolymer (ULDPE) available from the Dow Chemical Company. Film performance is reported in Table 6.

TABLE 3 Film line extruder setup Layer 1 Layer 5 (OUT) Layer 2 Layer 3 Layer 4 (IN) Extruder 50 60 90 60 50 diameter (mm) L/D 30 30 30 30 30 Grooved feed/ Grooved Grooved Grooved Smooth Grooved Smooth bore

TABLE 4 Film structure and composition Structure Layers 1, 2, 4, 5 # (Skins/Subskins) Layer 3 (Core) 1 100% Elite 5400GS 90% Elite 5400 GS + 10% Affinity PL1881G 2 100% Elite 5400GS 100% ULDPE 3 100% PE 1 100% PE 1 4 90% PE 1 + 10% LL1001XV 70% PE 1 + 30% LL1001XV 5 100% PE 3 100% PE 3 6 90% PE 3 + 10% LL1001XV 70% PE 3 + 30% LL1001XV 7 100% PE 4 100% PE 4

TABLE 5 Film processing conditions Layer 1 Layer 5 (OUT) Layer 2 Layer 3 Laver 4 (IN) Melt Melt Melt Melt Melt Melt Melt Melt Melt Melt Structure temp pressure temp pressure temp pressure temp pressure temp pressure # (° C.) (bar) (° C.) (bar) (° C.) (bar) (° C.) (bar) (° C.) (bar) 1 211 227 206 228 217 292 207 214 206 189 2 216 214 211 211 234 273 211 201 214 185 3 214 321 211 343 240 421 212 315 209 267 4 214 309 210 335 235 402 212 307 209 258 5 213 336 209 345 236 429 212 319 208 283 6 209 312 209 329 232 400 211 304 208 267 7 201 257 197 261 217 334 199 244 197 217

TABLE 6 Film Performance Needle Dart puncture- Needle puncture- Flex crack impact Max force energy at break Skins/Subskins Core (# of holes) (g/μm) (mN/μm) (mJ/μm) 100% Elite 5400GS 90% Elite 5400GS + 10% Affinity PL 1881G 10 22 50 0.14 100% Elite 5400GS 100% ULDPE 5 30 61 0.23 100% PE 1 100% PE 1 3 >40* 92 0.38 90% PE 1 + 10% LL1001XV 70% PE 1 + 30% LL1001XV 1 >40* 77 0.29 100% PE 3 100% PE 3 5 >40* 84 0.31 90% PE 3 + 10% LL1001XV 70% PE 3 + 30% LL1001XV 9 >40* 62 0.19 100% PE 4 100% PE 4 10 >40* 74 0.27 *Maximum of dart A method. Actual Dart impact value is higher than 40 g/μm.

The film made from PE 1 gave outstanding properties. It delivered substantially better flex crack resistance, dart drop impact strength, and puncture performance than the 2 reference structures. The film made from PE 3 also performed very well.

Additionally, introducing ZN C4 LLDPE resin with PE 1 (22% in the whole films) generally maintained flex crack resistance, dart drop impact strength, and puncture performance.

Example 3

PE 5, PE 6 and PE 7 resins were made according to the inventive polymers disclosed in Ser. No. 62/219,846, filed Sep. 17, 2015, using a solid zirconocene catalyst disclosed in U.S. Pat. No. 6,476,171, Col. 7, line 10, bridging Col. 8, line 26, under polymerization conditions to produce an ethylene-hexene copolymer having densities of 0.912-0.916 g/cm³.

PE 5 had a density of 0.916 g/cm³, a melt index (I_(2.16)) of 0.24 g/10 min, a melt index ratio (I_(21.6)/I_(2.16)) of 51, a hexene content of 3.0 mol %, a M_(n) of 37,170 g/mole, a M_(w) of 127848 g/mol and a M_(z) of 257800 g/mol.

PE 6 had a 0.916 g/cm³, a melt index (I_(2.16)) of 0.53 g/10 min, and a melt index 25 ratio (I_(2.16)/I_(2.16)) of 41, a hexene content of 3.4 mol %, a M_(n) of 32787 g/mol, a M_(w) of 108333 g/mol, and a M_(z) of 210560 g/mol.

PE 7 had a 0.913 g/cm³, a melt index (I_(2.16)) of 0.18 g/10 min, and a melt index 25 ratio (I_(21.6)/I_(2.16)) of 49, a hexene content of 3.9 mol %, a M_(n) of 38345 g/mol, a M_(w) of 139205 g/mol, and a M_(z) of 274045 g/mol.

PE 5-PE 7 were processed into blown films on a blown film line having 2½ inch (80 mm) extruder with 30 L/D ratio LLDPE screw, 6 inch (15.2 cm) diameter die, 30 mil (0.76 mm) die gap, and dual lip air ring with chilled air at round 60° F. The film line was operated at about 188 lbs (85 kg) per hour and 2.5 blow up ratio (BUR) producing 1.0 mil (25.4 μm) films for the resins. The film processing conditions are reported in Table 7. The flex crack resistance was measured and reported in Table 8.

TABLE 7 Film Processing Conditions Materials PE 5 film PE 6 film PE 7 film Melt pressure (psi) 5550 4370 6470 Melt temp. (° F.) 406 400 409 Gauge (mils) 1 0.99 1 FLH (in) 21 26 21

TABLE 8 Flex crack resistance (number of holes/10,000 cycles) Test 1 Test 2 Test 3 Test 4 Average PE 5 1 4 6 4 4 PE 6 9 11 12 7 10 PE 7 2 1 1 3 2

The phrases, unless otherwise specified, “consists essentially of” and “consisting essentially of” do not exclude the presence of other steps, elements, or materials, whether or not, specifically mentioned in this specification, so long as such steps, elements, or materials, do not affect the basic and novel characteristics of the invention, additionally, they do not exclude impurities and variances normally associated with the elements and materials used.

For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, within a range includes every point or individual value between its end points even though not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.

All priority documents are herein fully incorporated by reference for all jurisdictions in which such incorporation is permitted and to the extent such disclosure is consistent with the description of the present invention. Further, all documents and references cited herein, including testing procedures, publications, patents, journal articles, etc. are herein fully incorporated by reference for all jurisdictions in which such incorporation is permitted and to the extent such disclosure is consistent with the description of the present invention.

While the invention has been described with respect to a number of embodiments and examples, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope and spirit of the invention as disclosed herein. 

What is claimed is:
 1. A film made from at least one polyethylene polymer comprising from 75.0 mol % to 100.0 mol % ethylene derived units and having: a density of from 0.910 g/cm3 to 0.923 g/cm3, a melt index (I2.16) of from 0.1 g/10 min to 1.2 g/10 min, a melt index ratio (I21.6/I2.16) of from 20 to 35, and a weight average molecular weight (Mw) of from 150,000 g/mol to 400,000 g/mol; wherein the film has a dart drop impact strength (DIS) of ≥40 g/μm and flex crack resistance of ≤5 holes/10,000 cycles; and, wherein the film comprises two or more layers, wherein the two or more layers comprise at least one skin layer, a core layer, and optionally one or more intermediary layers; and, wherein at least one of the skin layer, the core layer, or optional intermediary layer comprises from 30 wt % to 100 wt % of the polyethylene polymer, based upon the total weight of the skin layer, the core layer, or optional intermediary layer; and, wherein at least one of the skin layer, the core layer, or optional intermediary layer, comprises a blend of the polyethylene polymer and at least one different polyethylene polymer, wherein the at least one different polyethylene polymer is a Ziegler-Natta linear low density polyethylene polymer.
 2. The film of claim 1, wherein the film has a flex crack resistance of ≤4 holes/10,000 cycles.
 3. The film of claim 1, wherein the film has a flex crack resistance of ≤3 holes/10,000 cycles.
 4. The film of claim 1, wherein the film has a dart drop impact strength (DIS) of ≥60 g/μm.
 5. The film of claim 1, wherein the film has a dart drop impact strength (DIS) of ≥80 g/μm.
 6. The film of claim 1, wherein the film has a film thickness of from ≥1 mil.
 7. The film of claim 1, wherein the film has a film thickness of from ≥3 mil.
 8. The film of claim 1, wherein the polyethylene polymer has a density of from 0.910 g/cm3 to 0.920 g/cm3.
 9. The film of claim 1, wherein the polyethylene polymer has a density of from 0.912 g/cm3 to 0.918 g/cm3.
 10. The film of claim 1, wherein the polyethylene polymer has a melt index (I2.16) of from 0.2 g/10 min to 1.1 g/10 min.
 11. The film of claim 1, wherein the polyethylene polymer has a melt index (I2.16) of from 0.4 g/10 min to 1.0 g/10 min.
 12. The film of claim 1, wherein the polyethylene polymer has a melt index ratio (I21.6/I2.16) of from 25 to
 32. 13. The film of claim 1, wherein the polyethylene polymer has a melt index ratio (I21.6/I2.16) of from 28 to
 31. 14. The film of claim 1, wherein the polyethylene polymer has an orthogonal comonomer distribution and/or has at least a first peak and at least a second peak in a comonomer distribution analysis.
 15. The film of claim 1, wherein the polyethylene polymer has a hafnium to zirconium ratio (ppm/ppm) ≥1.0.
 16. The film of claim 1, wherein the polyethylene polymer composition has at least a first peak and a second peak in a comonomer distribution analysis and wherein the first peak has a maximum at a log(Mw) value of 4.0 to 5.4 and a TREF elution temperature of 70.0° C. to 100.0° C. and the second peak has a maximum at a log(Mw) value of 5.0 to 6.0 and a TREF elution temperature of 40.0° C. to 70.0° C.
 17. The film of claim 1, wherein the ethylene-based polymer composition has at least a first peak and a second peak in a comonomer distribution analysis, wherein the first peak has a maximum at a log(Mw) value of 4.3 to 5.0 and a TREF elution temperature of 80.0° C. to 95.0° C. and the second peak has a maximum at a log(Mw) value of 5.3 to 5.7 and a TREF elution temperature of 45.0° C. to 60.0° C.
 18. The film of claim 1, wherein the ethylene-based polymer composition has at least a first peak and a second peak in a comonomer distribution analysis, wherein the first peak has a maximum at a log(Mw) value of 4.5 to 4.7 and a TREF elution temperature of 85.0° C. to 90.0° C. and the second peak has a maximum at a log(Mw) value of 5.4 to 5.6 and a TREF elution temperature of 48.0° C. to 54.0° C.
 19. The film of claim 1, wherein at least one of the skin layer, the core layer, or optional intermediary layer comprises from 50 wt % to 100 wt % of the polyethylene polymer, based upon the total weight of the skin layer, the core layer, or optional intermediary layer.
 20. A multilayer film comprising a core layer with a subskin layer located on each side of the core layer and a skin layer on the outer side of each subskin layer, where the core layer comprises i) from 50 wt % to 100 wt % of a first polyethylene polymer comprising from 75.0 mol % to 100.0 mol % ethylene derived units and having: a density of from 0.910 g/cm3 to 0.923 g/cm3, a melt index (I2.16) of from 0.1 g/10 min to 1.2 g/10 min, a melt index ratio (I21.6/I2.16) of from 20 to 35, and a weight average molecular weight (Mw) of from 150,000 g/mol to 400,000 g/mol; ii) a second polyethylene polymer comprising a Ziegler-Natta linear low density polyethylene polymer; the skin and subskin layers comprise i) from 50 wt % to 100 wt % of the first polyethylene polymer and ii) the second polyethylene polymer; wherein the wt % of first polyethylene polymer in the core layer is greater than or equal to the wt % of first polyethylene polymer in the skin and subskin layers; and wherein the film has a dart drop impact strength (DIS) of ≥40 g/μm and flex crack resistance of ≤5 holes/10,000 cycles. 